Rail bond



April 1939- w. P. BOVARD 2,155,217

RAIL BOND I Filed Feb. 4, 1937,

1n venlor WILLIAM '1 30104190 Attorney Patented Apr. 18, 1939 UNITEDSTATES PATENT OFFICE RAIL BOND corporation of New Jersey ApplicationFebruary 4, 1937, Serial No. 123,950

7 Claims.

My invention relates to rail bonds for electrically connecting theadjacent ends of rails conducting current.

The object of my invention is to provide a bond having a portion adaptedfor insertion in an opening or cavity in a portion of the rail,preferably the side of the rail head, and which can be expanded so as tosecurely engage the side wall of the opening or cavity in the rail.

A further object of my invention is to provide a bond which can beeasily and simply installed as by means of a hammer.

My invention resides in the new and novel construction, combination, andrelation of the parts hereinafter described and shown in the drawingaccompanying this specification.

In the drawing:

Fig. 1 is a side view of a single terminal and conductor.

Fig. 2 is a longitudinal view in partial section of the terminal andconductor shown in Fig. 1.

Fig. 3 is a sectional view taken on the line 3-3 of Fig. 1.

Fig. 4 isa side View of a pin I use and later 5 describe.

Fig. 5 is a sectional view taken on the line 55' of Fig. 3. v

Fig. 6 is a modified form of one end of the pin I use.

Fig. '7 is a sectional view of a modification of the terminal I use andwhich corresponds to a section taken on the line 33 of Fig. 1.

Fig. 8 shows a bond terminal assembled in a rail prior to the finalinstallation.

Fig. 9 is a View showing a terminal completely installed in a cavity ina rail head.

In the preferred embodiment of my invention, I provide a conductor whichmay be of copper, bronze, or steel. The copper conductor will, of

course, give the lowest resistance to the flow of current. The conductoris cut to the length required, and secured to each end is a terminal 2.I have shown the conductor with a terminal at one end only, and bondsare very often so constructed, but the majority of bonds comprise thecable I with two terminals 2, one at each end of the conductor.

The terminal 2 comprises a drive portion 3 with a portion 4 projectingtherefrom for insertion in the cavity 5 of the rail 6. The portions 3and t may be made of ferrous or non-ferrous metal, the former preferredas for instance, a soft or deformable steel such as forging steel. Themember 3 has a projecting sleeve 1.

55 The portion 4 is provided with a channel 8 and form diameter and abifurcated end l2 comprising the spaced prongs l3 forming the slot I4.The pin it is made preferably of a heat treated steel such as an alloysteel so treated that it is tough and as hard as or harder than thesteel 10 of the terminal portion 4, yet the prongs [3 being bendable asindicated by the dotted lines in Fig. 4.

The pin I0 is also provided with a portion I5 formed with a taper. Theportions II and I5 of 15 the pin H] are provided with ribs l6 which cutinto the portions of the terminal to prevent rotation of the pinrelative to the terminal after assembly.

The pin l [I is also provided with a head portion 90 ll which has ashoulder face l8 and a tapered end face I9, the latter correspondingwith the end wall 2% of the cavity 5 in the rail head.

The terminal portion 4 is provided with an end face 21. Positionedbetween the faces l8 and 2| 5 is a sleeve 22 preferably of copper orother nonferrous metal. The sleeve 22 may be omitted, if desired, andthe metal of the portion 4 extended to the face l8 as shown in Fig. 7.

I prefer the portion of the terminal 22 to be 30 of copper as it is morecompressible, easily deformable, expanding in those directions in whichit is unrestricted, at the same time it tends to harden as the metaldeforms. I find that after the bond terminal has been installed, thepor- 35 tion 22 of the terminal may have even embedded itself into orinterlocked with the wall of the cavity.

In constructing my invention, the parts 3 and 4 are forged or pressedfrom the metal desired preferably soft steel and the channels 8 and 9formed therein as by drilling. The channel 9 may extend only to thechannel 8 or it may extend beyond the channel 8 as shown in Fig. 2. Inthe latter case the conductor will be locked in place by the bifurcatedend of the pin ID as well as by the compression of the walls of theportions 3 and I.

The pin is constructed as herein before described and the copper sleeve22 likewise.

The parts having been formed, the cable is first positioned in thechannel 9 then the pin is positioned in the channel 8 as far as possiblewith the sleeve 22 in position on the pin.

The parts are then pressed together axially which forces the pin I0 intofinal position as shown in Figs. 2 and 3. As the split end of the pinengages with the conductor I, the ends are spread as shown in Fig. 3 orby the dotted lines in Fig. 4. This interlocks the pin with the driveportion 3 and also interlocks the pin with the conductor I.

In forcing the parts together the walls of the portions 3 and i of theterminal are forced into intimate and close engagement with the conductor I thus providing a connection between the parts which will preventtheir separation.

The forcing together of the parts into their final position is bestbrought about by placing the partially assembled parts in suitable diesand subjecting the same to pressure as by means of a stamping orhydraulic press or other apparatus well known to those skilled in theart, thus the size and relation of the parts will be .better maintained.

, The installation of my invention, comprises the drilling of a cavitypreferably in the side face 7 of each rail head adjacent the ends of thejuxta- 'to the terminal will force the part 4 into the cavity as shownin Fig. 9. In applying the force to the head 3, the member '22 being ofrelative soft metal and being brought under compression between'thefaces l8 and 2! (see Fig. 2), the same 'willbe expanded and forced into;intimate and binding engagement with the side wall of the cavity '5..Further application of force tothe member 3 will cause the portion 4 toshorten thus tending to increase its diameter and force the portionlinto binding engagement with the wall of the cavity 5. v If the coppersleeve 22 is omitted'and the portion 4 of the terminal extended to theface l8 of the pin as shown in Fig. '7, then the entire portion 4 willin time be shortened and simultaneously increased in diameter underforce applied to the portion 3 which in turn will cause a bindingengagement between the portion 4 of the terminal and the wall of thecavity 5.

As previously stated, the parts of my invention may be formed of variousmetals and combinations thereof, but I prefer to have the pin Ill of ashard a metal and a tougher metal than the r the cavity.

other parts, yet not so hard that the prongs l3 will not bend in theassembled operation. It is notmy intent that the portions H and I5 ofthe pin shall expand during the installation of the bond. I

During the installation the portions 3 and 4 may slide upon the pin I0since the free end of the pin is held by the end face 29 of the cavity 5and force is applied to the portion 3. This movement of parts duringinstallation tends to tighten the bifurcated end of the pin with respectto the conductor I and terminal portion 3.

Itwill be noted that the distances a and b are equal in Figs. 8' and 9showingthat the extra length of the parts 4 and 22 has been forced intoHaving disclosed my invention, modifications will suggest themselves tothose skilled in the art; therefore, I wish to be limited only by myclaims.

I claim:

1. The combination with a rail having a cavity therein of a rail bondcomprising a terminal adapted to be installed in the cavity in the railand a conductor secured to the terminal, the terminal comprising a driveportion having a channel therein for the reception of the conductor anda second portion projecting from the drive portion and having a channeltherethrough which intersects the first channel at substantially rightangles thereto, the said second portion being adapted to be inserted ina rail cavity to extend therein'short of the end wall of the cavity,

a headed pin having a part extending through the last said channel andinto the first channel to engage the conductor therein and forming athird portion of the terminal, the said second portion of the terminalhaving an end face spaced from the head of the pin and a ring of copperforming a fourth portion of the terminal positioned in the said spaceand encircling the pin, the diameter of the second and the fourthportions and the head of the third portion being equal and the totallength of these portions being greater than the depth of the railcavity, the said second and fourth portions of the terminal beingexpandable in the rail cavity into binding engagement with the wall ofthe rail cavity when force is applied to the said drive portion of theterminal.

2. A rail bond comprising a terminal with a conductor secured thereto,the terminal comprising a drive portion having a channel therein for thereception of the conductor and a second portion projecting from thedrive portion and having a channel therethrough which intersects thefirst channel at substantially right angles thereto, the said secondportion being adapted to be inserted in a rail cavity to extend thereinshort of the end wall of the cavity, a headed pin having a partextending through the last said channel and into 7 the first channel toengage the conductor therein and forming a third portion of theterminal, the said pin having a tapered part connecting it to the saidfirst part, the said second portion of the terminal having an end facespaced from the head of the pin and a collar of non-ferrous metal.forming a fourth portion of the terminal positioned in the said spaceand encircling the tapered part of the pin, the second and fourthportions of the terminal being expandable into bind- .ing engagementwith the wall of the rail cavity when force is applied to the driveportion.

3. A rail bond comprising in combination a conductor and a terminalsecured thereto, the said terminal comprising a drive portion havingmeans for securing the conductor thereto, and a second portion forinsertion in a rail cavity, the second portion provided with a channeland a headed pin forming a third portion of the terminal mounted in thechannel with the head spaced away from the end, face of the secondportion,

the terminal having a fourth portion. of nonconductor and a terminalsecured thereto, the said terminal comprising a drive portion havingmeans to secure the conductor thereto and a second portion forinsertion. in a rail cavity, the second portion having a channeltherethrough, a pin forming a third portion of the terminal mounted inthe channel and contacting with the conductor and having a head toengage the end wall of the rail cavity, the pin being slidable relativeto the conductor in an axial direction relative to the said secondportion of the terminal when force is applied to the drive portiontending toforce the conductor and pin into closer engagement and toexpand the end of the second portion of the terminal into close contactwith the side wall of the rail cavity.

5. The combination with a rail having a cavity therein of a rail bondcomprising a terminal adapted to be installed in a cavity in the railand a conductor secured to the terminal, the terminal being providedwith a drive portion and a second portion adapted to enter and beexpanded in the rail cavity, the said second portion having a channeland a pin positioned in the channel, the pin having a bifurcated endengaging the conductor and the other end exposed for contact with theend wall of the rail cavity, the pin adapted to be forced into strongerengagement with the conductor and the said second portion of theterminal adapted to be forced into tight engagement with the side wallof the rail cavity when force is applied to the drive portion of theterminal.

6. A rail bond comprising a terminal and a conductor secured thereto,the terminal compris; ing a drive portion and a second portion adaptedto enter and be expanded in arail cavity, the said second portion havinga channel extending axially thereof and a pin of hardermaterial thansaid second portion mounted in the channel and having one end extendinginto the said drive portion and engaging the conductor and interlockedwith the drive portion to prevent its withdrawal therefrom, means on thepin to interlock with the said second portion of the terminal to preventrelative rotation of the pin and said second portion, the pin having atapered portion atone end to expand the enclosed end of the secondportion of the terminal when the said second portion of the terminal isforced into the rail cavity.

7. A rail bond terminal for installation in a rail cavity comprising apart adapted to receive a conductor and a second part to be insertedWithin the rail cavity, the latter part of the terminal having aseparately formed central portion of relatively softer material than theother portion, and adapted to be expanded into holding engagement withthe side wall of the rail cavity when the said second part is forcedinto the rail cavity.

WILLIAM P. BOVARD.

